Channel system for a vacuum insulated structure

ABSTRACT

An appliance includes a panel having a raised landing outwardly extending from a first surface of the panel. A vacuum port is disposed on the raised landing. A system of channels is disposed over the first surface of the panel and outwardly extends therefrom. The system of channels substantially covers the first surface of the panel. The first surface of the panel is covered with a filter member that covers the system of channels. The raised landing, and vacuum port thereof, is fluidically coupled to the system of channels at multiple connecting locations.

BACKGROUND

The present concept generally relates to a channel system for a vacuuminsulated structure, and more specifically, to a channel system that isembossed on a panel of an outer wrapper to provide a faster evacuationof the vacuum insulated structure.

SUMMARY

In at least one aspect, an appliance includes an outer wrapper having afirst surface and a plurality of channels disposed along the firstsurface of the outer wrapper. A trim breaker interconnects the outerwrapper and an inner liner in an air-tight manner to define aninsulation space therebetween. A vacuum port is disposed on the outerwrapper and is fluidically coupled to the plurality of channels.

In at least another aspect, an appliance includes a panel having araised landing outwardly extending from a first surface of the panel. Avacuum port is disposed on the raised landing. A system of channels isdisposed over the first surface of the panel and outwardly extendstherefrom. First and second interconnecting channels are disposed on thepanel and each include first ends fluidically coupled to the raisedlanding and second ends fluidically coupled to the system of channels atfirst and second connecting locations along the system of channels.

In at least another aspect, an appliance includes a panel having avacuum port disposed thereon. A system of channels defining a channelloop is disposed over the panel. The channel loop includes a first endand a second end with a body portion disposed therebetween. The firstend and the second end of the channel loop are fluidically coupled tothe vacuum port.

These and other features, advantages, and objects of the present devicewill be further understood and appreciated by those skilled in the artupon studying the following specification, claims, and appendeddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1A is a front elevation view of an appliance for use with thepresent concept;

FIG. 1B is a front elevation view of the appliance of FIG. 1A with thedoors open to reveal a refrigerator compartment;

FIG. 2 is a rear perspective view of the appliance of FIG. 1A;

FIG. 3A is a perspective view of a panel of the appliance of FIG. 1Ahaving a channel system embossed on an inner surface thereof and with afilter member and an adhesive member exploded away therefrom;

FIG. 3B is a zoomed-in view of a raised landing of the panel of FIG. 3A;

FIG. 4 is a perspective view of the panel of FIG. 3A with the filtermember and the adhesive member coupled to the inner surface of the panelto cover the system of channels;

FIG. 5 is a cross-sectional view of the panel of FIG. 4 taken at line V;and

FIG. 6 is a cross-sectional view of the panel of FIG. 4 taken at lineVI.

DETAILED DESCRIPTION OF EMBODIMENTS

For purposes of description herein the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the device as oriented in FIG. 1. However, it isto be understood that the device may assume various alternativeorientations and step sequences, except where expressly specified to thecontrary. It is also to be understood that the specific devices andprocesses illustrated in the attached drawings, and described in thefollowing specification are simply exemplary embodiments of theinventive concepts defined in the appended claims. Hence, specificdimensions and other physical characteristics relating to theembodiments disclosed herein are not to be considered as limiting,unless the claims expressly state otherwise.

Referring now to FIGS. 1A-2, reference numeral 10 generally designatesan appliance having a vacuum insulated structure 11 which includes anouter wrapper 12 that defines a top wall 14, a bottom wall 16, a rearwall 18, and first and second side walls 20, 22, and further includes aninner liner 24. A trim breaker 26 seals the outer wrapper 12 to theinner liner 24 to define an insulation space 30 (FIG. 1B) therebetween.A single vacuum port 32 (FIG. 2) is disposed on each of the top wall 14,the bottom wall 16, and the first and second side walls 20, 22. It iscontemplated that any number of vacuum ports 32 may be provided on theouter walls of the outer wrapper 12, such that the present concept isnot limited to the configuration of vacuum ports 32 shown in FIG. 2.

With reference again to FIGS. 1A-1B, the illustrated appliance 10 is arefrigerator assembly that includes French doors 46, 48 that arepivotally coupled to a refrigerator compartment 49 and operable betweenopen and closed positions. The refrigerator assembly also includes alower pull out drawer 57 that defines a freezer compartment 58. It willgenerally be understood that the features, as set forth herein, could beapplied to any appliance having any general configuration. Further, thedoor configuration of the appliance 10 can vary from that shown in FIG.1A. The doors 46, 48, as illustrated in FIG. 1A, include handles 60configured to allow a user to move the doors 46, 48 between open andclosed positions. The refrigerator compartment 49 and the freezercompartment 58 include shelving 62, as shown in FIG. 1B, that can beadjusted and moved, depending on consumer preference. The outer wrapper12 of the appliance 10 is contemplated to be generally formed from ametal material, which may be steel, aluminum, etc. The inner liner 24 isalso contemplated to be constructed from a metal material, which may besteel, aluminum, etc. However, sealed plastics, or other materials thatcan maintain an air-tight seal, could also be used in conjunction withthe systems, as set forth herein.

With reference now to FIG. 2, the illustrated embodiment includes aplurality of vacuum ports 32 that are spaced at predetermined positionson the outer wrapper 12 to draw a sufficient amount of vacuum from areasof the insulation space 30 (FIG. 1B). An insulation material 34 (FIGS. 5and 6) is disposed between the outer wrapper 12 and the inner liner 24within the insulation space 30. A filter member 40 (FIG. 3A) is disposedproximate each vacuum port 32 (FIG. 5), such that air can be drawn fromthe insulation space 30 past the filter member 40 and through eachvacuum port 32. Evacuation of the insulation space 30 via vacuum port 32is further described below in conjunction with a system providingimproved evacuation efficiency for the present concept.

As a result of the additional vacuum ports 32, the total vacuum time toplace the insulation material 34 in a vacuum state and draw fluid (inthe form of air) from the insulation space 30 is lessened. Consequently,refrigerator assemblies can be constructed at a faster rate and with agreater degree of negative pressure between the inner liner 24 and theouter wrapper 12. Each of the vacuum ports 32 is contemplated to includea valve system 70 configured to prevent air from entering the insulationspace 30 after the vacuum process has been completed. In the illustratedembodiment of FIG. 2, a vacuum port 32 is disposed on each of the topwall 14, the bottom wall 16, the rear wall 18, and the first and secondside walls 20, 22 of the outer wrapper 12. However, it will be notedthat more vacuum ports 32 could be disposed on any of the top wall 14,the bottom wall 16, the rear wall 18, and the first and second sidewalls 20, 22 of the outer wrapper 12 to increase the speed in which anegative pressure is obtained within the insulation space 30.

In some instances, the vacuum ports 32 may be removed from certain wallsof the appliance 10. For example, in the event the appliance 10 willhave exposed first and second side walls 20, 22 that are readilyviewable by the consumer, the vacuum ports 32 may be omitted from thefirst and second side walls 20, 22. In this instance, additional vacuumports 32 may be disposed on first and second sides of the top wall 14proximate the first and second side walls 20, 22 or on first and secondsides of the bottom wall 16 in close proximity to the first and secondside walls 20, 22. In addition, more vacuum ports 32 on the rear wall 18may also be positioned on the outer wrapper 12 to compensate for theloss of a vacuum port 32 of each of the first and second side walls 20,22. The valve system 70 incorporated into the vacuum ports 32 areconfigured to attach to a vacuum hose and may include ball valves,butterfly valves, check valves, choke valves, diaphragm valves, gatevalves, globe valves, poppet valves, etc. A simple crimping solution oran end cap can also be used to close the vacuum hose. It will beunderstood that any kind and any number of valves may be used and thatthis disclosure is not limited by any of the valve systems noted above.

It will be understood that the inner liner 24 and the outer wrapper 12are connected at the trim breaker 26 generally disposed proximate theopening of the appliance 10, as shown in FIG. 1B. The trim breaker 26 issealed and air-tight, such that air can neither escape nor enter intothe insulation space 30 between the outer wrapper 12 and the inner liner24 at the trim breaker 26. In addition, it will be understood that theinsulation material 34 can be disposed throughout the appliance 10 inthe insulation space 30. During assembly of the appliance 10, theinsulation material 34 is poured, blown or otherwise inserted, into theinsulation space 30 before the insulation space 30 is sealed air-tight.In addition, it will be noted that, as illustrated in FIG. 5, the filtermember 40 is disposed between the vacuum port 32 and the insulationmaterial 34. The filter member 40 acts to prevent insulation material 34from being drawn through the vacuum port 32 when a negative pressure isplaced on the insulation space 30. Accordingly, the insulation material34 is maintained in the insulation space 30 between the outer wrapper 12and the inner liner 24 as air is drawn from the insulation space 30 andinsulation member 34 by an external vacuum pump and filtered by thefilter member 40.

As further shown in FIG. 2, the rear wall 18 of the outer wrapper 12includes a panel 21 which has a plurality of channels 80 which defines asystem of channels. In the embodiment shown in FIG. 2, the plurality ofchannels 80 defining the system of channels of the panel 21 includes anumber of vertical channels 82A-82D and upper and lower cross channels84A, 84B. Vertical channels 82A, 82D are interconnected with the upperand lower cross channels 84A, 84B to define an outer perimeter 86 of thesystem of channels 80. As used herein, the term “system of channels” isused to describe a series of interconnected and multi-directionalchannels that may define a channel loop 88 within the system of channels80. The channel loop 88 may be disposed along the outer perimeter 86 ofthe channel system 80. The channel loop 88 may also include intermediatechannels, such as vertical channels 82B, 82C. The plurality of channels80 are disposed on an outer surface 21A of the panel 21 and arecontemplated to be created by an embossing process or stamping processthat creates the plurality of channels 80 in a manner such that theplurality of channels 80 outwardly extends from the outer surface 21A ofthe panel 21.

As further shown in FIG. 2, the panel 21 also includes a raised landing90 upon which the vacuum port 32 is disposed. The raised landing 90 isfluidically interconnected with the plurality of channels 80 viainterconnecting channels 102A, 102B. Each of the interconnectingchannels 102A, 102B include a first end 104 (FIG. 3B) that isfluidically coupled to the raised landing 90 and a second end 106 (FIG.3B) that is fluidically coupled to the system of channels 80. In thisway, the second ends 106 of the interconnecting channels 102A, 102Bdefine first and second connecting locations along the system ofchannels 80 that are spaced-apart from one another and independent ofone another. Thus, in the embodiment shown in FIGS. 2 and 3B, the raisedlanding 90 includes a plurality of interconnections to the system ofchannels 80 that allows for fluid communication between the raisedlanding 90 and the system of channels 80 at multiple locations. With thesystem of channels 80 and the raised landing 90 in fluid communicationvia multiple interconnecting channels 102A, 102B, the vacuum port 32 ofthe raised landing 90 is also in fluid communication with the system ofchannels 80. In this way, the vacuum port 32 can pull air anywhere alongthe length of the system of channels 80 to quickly evacuate the vacuuminsulated structure 11. With this configuration, airflow from the systemof channels 80 can be drawn to the raised landing 90 and the vacuum port32 of the panel 21 via multiple directional airflow paths AF1, AF2. Asfurther shown in FIG. 2, the system of channels 80, having verticalchannels 82A-82D and upper and lower cross channels 84A, 84Bspaced-apart along the outer surface 21A of the panel 21, the system ofchannels 80 substantially covers the panel 21. As used in this context,the term “substantially” is meant to define coverage of the panel 21 bythe system of channels 80 that is commensurate with the overall lengthand width of the panel 21. Thus, in this case, the panel 21 issubstantially covered by the system of channels 80 at the outer surface21A of the panel 21 given that the vertical channels 82A-82D and theupper and lower cross channels 84A, 84B substantially span or cover thelength and width of the panel 21.

With further reference to the embodiment shown in FIG. 2, the channelloop 88 may include a first end that is defined by the first connectinglocation (end 104 or end 106 of interconnecting channel 102A) and asecond end that is defined by the second connecting location (end 104 orend 106 of interconnecting channel 102B) with a body portion of thechannel loop 88 defined by the vertical channels 82A-82D and the upperand lower cross channels 84A, 84B.

Referring now to FIG. 3A, the panel 21 is shown from an inner surface21B thereof. The system of channels 80 is shown as being inset from theinner surface 21B of the panel 21, as opposed to outwardly extendingfrom the outer surface 21A of the panel 21 shown in FIG. 2. In FIG. 3A,a filter member 40 is shown having a body portion 42 with an outerperimeter edge 44. The filter member 40 is shown in FIG. 3A as explodedaway from the inner surface 21B of the panel 21, however, it iscontemplated that the filter member 40 is affixed to the inner surface21B of the panel 21 in assembly, and is sized appropriately to cover theentirety of the system of channels 80, the raised landing 90 and thevacuum port 32 of the panel 21. The filter member 40 is contemplated tobe comprised of a sheet of paper material which is configured to allowfor the passage of air from the insulation space 30 to the system ofchannels 80, while retaining the insulation material 34 within theinsulation space 30. Thus, the paper material of the filter member 40may be a filter paper material that is porous to airflow, but preventsthe insulation material 34 from entering the system of channels 80during an evacuation procedure. Being sized to cover the entirety of thesystem of channels 80, the filter member 40 substantially covers theinner surface 21B of the panel 21 in assembly, as shown in FIG. 4. Asused in this context, the term “substantially” is meant to definecoverage of the panel 21 by the filter member 40 that is commensuratewith the overall length and width of the panel 21. The filter member 40is affixed to the inner surface 21B of the panel 21 by an adhesivemember 50. The adhesive member 50 includes a frame assembly 52 thatsubstantially follows the contours of the outer perimeter edge 44 of thefilter member 40. In this way, the adhesive member 50 can be used tointerconnect the inner surface 21B of the panel 21 and the filter member40 by the frame assembly 52 surrounding the outer perimeter edge 44 ofthe filter member 40. Specifically, the adhesive member 50 includes afirst portion 54 which is configured to couple to the inner surface 21Bof the panel 21, and a second portion 56 which is configured to adhereto the filter member 40 adjacent the outer perimeter edge 44 thereof.Coupling of the filter member 40 to the panel 21 using the first andsecond portions 54, 56 of the adhesive member 50 is shown in FIGS. 5 and6. In this way, when the adhesive member 50 interconnects the filtermember 40 and the inner surface 21B of the panel 21, the filter member40 will remain in place over the system of channels 80 as best shown inFIG. 4.

Referring now to FIG. 5, a portion of the vacuum insulated structure 11is shown, wherein the trim breaker 26 interconnects the panel 21 of theouter wrapper 12 and the inner liner 24 in an air-tight manner to definethe insulation space 30 therebetween. A vacuum port 32 is shown disposedon the panel 21 of the outer wrapper 12 at the raised landing 90thereof. The vacuum port 32 is shown as being fluidically coupled to aninterconnecting channel 102B which, as noted above, is fluidicallycoupled to the system of channels defined by the plurality of channels80. As further shown in FIG. 5, the filter member 40 covers the innersurface 21B of the panel 21 adjacent the location of the raised landing90 and the vacuum port 32. As noted above, the filter member 40substantially covers the inner surface 21B of the panel 21, such thatthe filter member 40 covers the entirety of the system of channels 80,the raised landing 90 and the vacuum port 32. As further shown in FIG.5, the adhesive member 50 includes portions 54 and 56 which are coupledto and interconnect the inner surface 21B of the panel 21 and the filtermember 40, respectively. It is contemplated that the adhesive member 50may include a one-sided tape material.

Referring now to FIG. 6, a portion of the vacuum insulated structure 11is shown, wherein the trim breaker 26 interconnects the panel 21 of theouter wrapper 12 and the inner liner 24 in an air-tight manner to definethe insulation space 30 therebetween. An insulation material 34 is showndisposed within the insulation space 30 in FIGS. 5 and 6. A verticalchannel 82A of the system of channels 80 is shown in FIG. 6 as beingdisposed on the panel 21 of the outer wrapper 12. The vertical channel82A is shown as being inset from the inner surface 21B of the panel 21and, as a corollary, the vertical channel 82A is shown extendingoutwardly from the outer surface 21A of the panel 21. As further shownin FIG. 6, the filter member 40 covers the inner surface 21B of thepanel 21 adjacent the location of the vertical channel 82A. Thus, as avacuum is drawn on the vacuum insulated structure 11 via a vacuum port,such as vacuum port 32 shown in FIG. 5, a passage way 89 of the verticalchannel 82A remains clear for airflow to properly evacuate the vacuuminsulated structure 11. Thus, the filter member 40 prevents any of theinsulation materials 34 from entering the system of channels 80 when thevacuum insulated structure 11 is evacuated and pressurized.

A vacuum insulated structure, such as vacuum insulated structure 11described above, has very low heat gain due to the presence of a vacuuminside a highly porous structure reducing the heat transfer through gasconduction, convection and radiation. This vacuum is created by drawingthe air inside the vacuum insulated structure 11 using pumps coupled tothe vacuum ports 32 of the vacuum insulated structure 11. The process ofremoving air inside the insulation space 30 to create the vacuum is timeintensive. For example, a simple rectangular panel structure having thefollowing dimensions (1 m long×1 m wide×0.05 m thick) can take around 4days for a sufficient evacuation at a single vacuum port. The presentconcept helps to reduce evacuation time by about 70% by allowing air tobe drawn along an entire system of channels 80, as compared to a singleaperture at a vacuum port location. This particular concept provides adesign to reduce air travel distance during an evacuation procedure,which eventually reduces evacuation time. Here, vacuum channels maskingup the system of channels 80 are well connected to each other and alsowell connected to the vacuum port 32. To each channel of the system ofchannels is closed from an inner side thereof by a filter member 40 tocreate interior passage ways 89 (FIG. 6) between the filter member 40and the system of channels 80. This configuration allows air to passthrough the filter member 40 from the insulation space 30 and into thechannels of the system of channels 80 when a pump starts drawing from avacuum port that is fluidically coupled to the system of channels 80. Asthe system of channels 80 is widely spread all over the surface ofinsulation material 34, air disposed within the insulation material 34and within the insulation space 30 has a short distance to travel toreach the vacuum port, as opposed to a single aperture vacuum portsystem. This results in a faster evacuation time for a vacuum insulatedcabinet comprising the present concept.

It will be understood by one having ordinary skill in the art thatconstruction of the described device and other components is not limitedto any specific material. Other exemplary embodiments of the devicedisclosed herein may be formed from a wide variety of materials, unlessdescribed otherwise herein.

For purposes of this disclosure, the term “coupled” (in all of itsforms, couple, coupling, coupled, etc.) generally means the joining oftwo components (electrical or mechanical) directly or indirectly to oneanother. Such joining may be stationary in nature or movable in nature.Such joining may be achieved with the two components (electrical ormechanical) and any additional intermediate members being integrallyformed as a single unitary body with one another or with the twocomponents. Such joining may be permanent in nature or may be removableor releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement ofthe elements of the device as shown in the exemplary embodiments isillustrative only. Although only a few embodiments of the presentinnovations have been described in detail in this disclosure, thoseskilled in the art who review this disclosure will readily appreciatethat many modifications are possible (e.g., variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited. For example,elements shown as integrally formed may be constructed of multiple partsor elements shown as multiple parts may be integrally formed, theoperation of the interfaces may be reversed or otherwise varied, thelength or width of the structures and/or members or connector or otherelements of the system may be varied, the nature or number of adjustmentpositions provided between the elements may be varied. It should benoted that the elements and/or assemblies of the system may beconstructed from any of a wide variety of materials that providesufficient strength or durability, in any of a wide variety of colors,textures, and combinations. Accordingly, all such modifications areintended to be included within the scope of the present innovations.Other substitutions, modifications, changes, and omissions may be madein the design, operating conditions, and arrangement of the desired andother exemplary embodiments without departing from the spirit of thepresent innovations.

It will be understood that any described processes or steps withindescribed processes may be combined with other disclosed processes orsteps to form structures within the scope of the present device. Theexemplary structures and processes disclosed herein are for illustrativepurposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can bemade on the aforementioned structures and methods without departing fromthe concepts of the present device, and further it is to be understoodthat such concepts are intended to be covered by the following claimsunless these claims by their language expressly state otherwise.

The above description is considered that of the illustrated embodimentsonly.

Modifications of the device will occur to those skilled in the art andto those who make or use the device. Therefore, it is understood thatthe embodiments shown in the drawings and described above is merely forillustrative purposes and not intended to limit the scope of the device,which is defined by the following claims as interpreted according to theprinciples of patent law, including the Doctrine of Equivalents.

What is claimed is:
 1. An appliance comprising: an outer wrapper havinga first surface; a plurality of channels disposed along the firstsurface of the outer wrapper; an inner liner; a trim breakerinterconnecting the outer wrapper and the inner liner in a substantiallyair-tight manner to define an insulation space therebetween; and avacuum port disposed on the outer wrapper, wherein the vacuum port isfluidically coupled to the plurality of channels.
 2. The appliance ofclaim 1, wherein the outer wrapper and the inner liner are formed from ametal material.
 3. The appliance of claim 1, including: a filter memberdisposed over the plurality of channels, such that air can be drawn fromthe insulation space past the filter member and through the plurality ofchannels to the vacuum port to maintain a negative pressure in theinsulation space.
 4. The appliance of claim 3, wherein the filter memberis formed from a filter paper material.
 5. The appliance of claim 3,including: an adhesive member coupling an outer perimeter edge of thefilter member with the first surface of the outer wrapper.
 6. Theappliance of claim 3, including: an insulation material disposed in theinsulation space between the outer wrapper and the inner liner.
 7. Theappliance of claim 3, including: an adhesive member, wherein theadhesive member includes a frame assembly that surrounds an outerperimeter edge of the filter member, such that a first portion of theframe assembly is coupled to the first surface of the outer wrapper anda second portion of the frame assembly is coupled to the filter member.8. The appliance of claim 3, wherein the plurality of channels includesa first portion substantially covering a width of the first surface ofthe outer wrapper and a second portion substantially covering a lengthof the first surface of the outer wrapper.
 9. The appliance of claim 8,wherein the filter member substantially covers the first surface of theouter wrapper.
 10. An appliance comprising: a panel having a raisedlanding outwardly extending from a first surface of the panel; a vacuumport disposed on the raised landing; a system of channels having two ormore interconnected channels disposed over the first surface of thepanel and outwardly extending therefrom; and first and secondinterconnecting channels, wherein both the first and secondinterconnecting channels include first ends fluidically coupled to theraised landing and second ends fluidically coupled to the system ofchannels at first and second connecting locations along the system ofchannels.
 11. The appliance of claim 10, including: a filter memberdisposed over the system of channels, such that air can be filteredthrough the filter member along the system of channels.
 12. Theappliance of claim 11, wherein the filter member is formed from a papermaterial.
 13. The appliance of claim 11, including: an adhesive memberinterconnecting the filter member and a second surface of the panel overthe system of channels.
 14. The appliance of claim 13, wherein thefilter member substantially covers the second surface of the panel. 15.The appliance of claim 10, wherein the panel is formed from a metalmaterial, and further wherein the two or more interconnected channelsare embossed on the first surface of the panel.
 16. An appliancecomprising: a panel; a vacuum port disposed on the panel; and a one ormore channels defining a channel loop disposed over the panel, whereinthe channel loop includes a first end and a second end with a bodyportion disposed therebetween, and further wherein the first end and thesecond end of the channel loop are fluidically coupled to the vacuumport.
 17. The appliance of claim 16, including: a filter member disposedover the one or more channels, such that air can be drawn through thefilter member and to the vacuum port through the one or more channels.18. The appliance of claim 17, wherein the filter member is formed froma paper material.
 19. The appliance of claim 17, including: an adhesivemember interconnecting the filter member and a first surface of thepanel.
 20. The appliance of claim 19, wherein the filter membersubstantially covers the first surface of the panel.